EP0363225B1

EP0363225B1 - Valve spring retainer for valve operating mechanism for internal combustion engine

Info

Publication number: EP0363225B1
Application number: EP89310285A
Authority: EP
Inventors: Haruo C/O Kabushiki Kaisha Honda Shiina; Masami C/O Kabushiki Kaisha Honda Hoshi; Tadayoshi C/O Kabushiki Kaisha Honda Hayashi
Original assignee: Honda Motor Co Ltd
Current assignee: Honda Motor Co Ltd
Priority date: 1988-10-07
Filing date: 1989-10-06
Publication date: 1994-06-08
Anticipated expiration: 2009-10-06
Also published as: DE68915924T2; EP0363225A3; EP0363225A2; US4989556A; DE68915924D1; CA1327153C

Description

The field of the present invention is high strength aluminium alloys - such as known from EP-A-0 191 707 or EP-A-0 147 769 - and valve spring retainers for valve operating mechanisms for internal combustion engines, and particularly, lightweight valve spring retainers formed from aluminum alloys.
Such valve spring retainers have been conventionally made using a high strength aluminum alloy containing large amounts of Si, Fe, Mn, etc., added thereto, by utilizing a powder metallurgical technique.
However, the above aluminum alloy is accompanied by a problem: An initial crystal Si, an eutectic crystal Si, an intermetallic compound, etc., precipitated therein are very fine and hence, the resulting valve spring retainer may be subject to a large amount of slide wear and as a result, has a lack of durability under a high surface pressure and under a rapid sliding movement.
There is also such a known valve spring retainer which includes a flange portion at one end of an annular base portion that has a diameter larger than the base portion, with an annular end face of the flange portion serving as an outer seat surface for carrying an outer valve spring and with an annular end face of the base portion serving as an inner seat surface for carrying an inner valve spring.
The valve spring retainer is produced utilizing a powder metallurgical technique and hence, the structure and the hard grain dispersion in a surface layer region having the outer seat surface are substantially identical with those in a surface layer region having the inner seat surface.
In the above valve operating mechanism, the outer valve spring has a relatively high preset load, while the inner valve spring has a relatively low preset load. Therefore, in the valve spring retainer, the slide surface pressure on the outer seat surface is larger than that on the inner seat surface. Under such a situation, and if properties of the outer and inner seat surfaces are the same, a difference in the amount of wear will be produced between the two seat surfaces, thereby bringing about a variation in load distribution between the outer and inner valve springs.
In addition, because a valve spring retainer is disposed in a limited space in the valve operating system, it is designed so that the thickness of the flange portion may be decreased to reduce the amount of projection in the direction of its valve stem. Therefore, there is a tendency to generate a concentration of stress at the junction between the flange portion and the base portion. Accordingly, it is desired to improve the fatigue strength of such junction.
Further, if hydrogen gas is included in the aluminum alloy, the fatigue strength thereof is damaged. Therefore, it is a conventional practice to subject a powder compact to a degassing treatment, but this treatment may cause not only a reduction in production efficiency for the valve spring retainer, but also result in damaging the strength thereof.
Patent Abstracts of Japan, Vol. 12, No. 269 (M-723) [3116] discloses a valve spring retainer for a valve operating mechanism for an internal combustion engine, which is made of a Duralumin matrix having ceramic alumina particles dispersed therein.
It is an object of the present invention to provide an aluminum alloy improved in wear resistance, strength and the like and a mechanical structural member, eg. a valve spring retainer, manufactured therefrom.
To attain the above object, according to the present invention, there is provided a high strength aluminum alloy for a mechanical structural member, according to either of claims 1, 2, 3 and 4.
The matrix is conveniently formed from a quenched and solidified aluminum alloy powder.
In addition, according to the present invention, there is provided a mechanical structural member, such as a valve spring retainer, manufactured from such an alloy.
Further, according to the present invention, there is provided a valve spring retainer for a valve operating mechanism for an internal combustion engine, comprising a flange portion at one end of an annular base portion that has a diameter larger than that of the base portion, with an annular end face of the flange portion serving as an outer seat surface for carrying an outer valve spring and an annular end face of the base portion serving as an inner seat surface for carrying an inner valve spring, so that the flow pattern of the fiber structure of the material in a surface region having the outer seat surface is substantially parallel to the outer seat surface.
Yet further, according to the present invention, there is provided a valve spring retainer for a valve operating mechanism for an internal combustion engine, formed from a quenched and solidified aluminum alloy containing 0.2% to 4% by weight of at least one hydride forming constituent selected from the group consisting of Ti, Zr, Co, Pd and Ni.
If the amount of hard grain added and the area rate of the hard grain are specified, the dispersion of the hard grain in the matrix is optimal for improving the wear resistance of the matrix. In addition, the hard grain has an effect of fixing the dislocation of the crystal of the matrix to provide improvements in creep characteristic, stress corrosion and crack resistance, a reduction in thermal expansion coefficient, and improvements in Young's modulus and fatigue strength.
However, if the hard grain content is less than 0.5% by weight, the wear resistance is not improved, and the degrees of the improvement in Young's modulus and the decrease in thermal expansion coefficient are also lower. On the other hand, if the hard grain content is more than 20%, e.g., 25.0% by weight, the wearing of the valve spring is increased.
If the area rate of the hard grain is less than 1%, the wear resistance is insufficient. On the other hand, any area rate exceeding 6% will cause a deterioration of the stress corrosion and crack resistance and a reduction in fatigue strength.
The reason why each constituent is contained and the reason why the content thereof is limited are as follows:

(a) For Si
Si has an effect of improving the wear resistance, the Young's modulus and the thermal conductivity of the matrix and decreasing the thermal expansion coefficient of the matrix. However, If the amount of Si is less than 12.0% by weight, the above effect cannot be obtained. On the other hand, if the amount of Si is more than 28.0% by weight, the formability is degraded in the extruding and forging steps, resulting in the likelihood that cracks will be produced.
(b) For Cu
Cu has an effect of reinforcing the matrix in the thermal treatment. However, if the amount of Cu is less than 0.8% by weight, such effect cannot be obtained. On the other hand, if the amount of Cu is more than 5.0% by weight, the stress corrosion and crack resistance is degraded and the hot forging workabillty is reduced.
(c) For Mg
Mg has an effect of reinforcing the matrix in the thermal treatment as Cu does. However, if the amount of Mg is less than 0.3% by weight, such effect cannot be obtained. On the other hand, if the amount of Mg is more than 3.5% by weight, the stress corrosion and crack resistance is degraded and the hot forging workability is reduced.
(d) For Fe
Fe has an effect of improving the high-temperature strength and Young's modulus of the matrix. However, if the amount of Fe is less than 2.0% by weight, an improvement in high-temperature strength cannot be expected. On the other hand, if the amount of Fe is more than 10.0% by weight, the rapid hot forging is actually impossible.
(e) For Mn
Mn has an effect of improving the high-temperature strength and the stress corrosion and crack resistance of the matrix and enhancing the hot forging workability in a range of Fe ≧ 4. If the amount of Mn is less than 0.5%, however, such effect cannot be obtained. On the other hand, if the amount of Mn is exceeds 2.0% by weight, adverse influences arise, and for example, the hot forging workability is rather degraded.

The hard grain particles are linearly arranged along the flow pattern of the fiber structure in the outer seat surface and hence, the area rate of the hard grain on the outer seat surface is higher. This improves the wear resistance of the outer seat surface.
Further, the hydrogen gas in the aluminum alloy can be fixed in the form of a hydride, so that the fatigue strength of such alloy and thus the valve spring retainer can be improved. In addition, because this alloy cannot be limited by the amount of hydrogen gas, there is no need to consider the degassing treatment. Therefore, in producing the alloy, it is possible to employ a powder direct-forming process comprising a powder pressing step directly followed by a forging step rather than comprising a powder pressing step, an extruding step and a forging step which are conducted in sequence. This makes it possible to simplify the production of an alloy to improve the mass productivity thereof.
However, if the content of the hydride forming constituent is less than 0.2% by weight, the hydride forming action is declined. On the other hand, any content of the hydride forming constituent exceeding 4% by weight will result in a problem of reductions in elongation and toughness.
The above and other objects, features and advantages of the invention will become apparent from a reading of the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig.1 is a sectional view of a valve operating mechanism for an internal combustion engine;
Fig.2 is a perspective view of a wear resistant aluminum alloy formed by a hot extrusion;
Fig.3A is a diagram for explaining how the aluminum alloy is cut into a first test piece;
Fig.3B is a diagram for explaining how the aluminum alloy is cut into a second test piece;
Fig.4A is a daigram illustrating a flow pattern of a fiber structure of a material in a valve spring retainer according to the present invention;
Fig.4B is a daigram illustrating a flow pattern of a fiber structure of a material in a valve spring retainer of a comparative example;
Figs.5A to 5E are diagrams for explaining steps of producing the valve spring retainer by forging;
Fig.6 is a view for explaining a cutting process for the valve spring retainer of the comparative example;
Fig.7 is a sectional view of the valve spring retainer;
Fig.8 is a graph illustrating a relationship between the amount of hard grains added and the like, and the properties of the valve spring retainer and the valve spring; and
Fig.9 is a graph illustrating a relationship between the average particle size of the hard grain and the amount of hard grain added in a hardness Hv of 700 to 3,000 of the hard grain.

Fig.1 illustrates a valve operating mechanism V for an internal combustion engine E, in which a valve spring retainer 4 is secured to a leading end of a valve stem 3 of an intake valve 2 slidably mounted in a cylinder head 1. The valve spring retainer 4 comprises an annular base portion 5, a flange portion 6 located at one end of the base portion 5, an annular projection 7 located at the other end of the base portion 5. The flange portion 6 is larger in diameter and smaller in thickness than the base portion 5. The projection 7 is smaller in diameter than the base portion 5 and has its outer peripheral surface formed into a tapered surface convergent toward an outer end face 7a. An annular end face of the flange portion 6 is an outer seat surface 8, and an annular end face of the base portion 5 is an inner seat surface 9. Thus, the projection 7 projects from an inner peripheral edge of the inner seat surface 9.
An outer valve spring 10 is carried at one end thereof on the outer seat surface 8, and an inner valve spring 11 is carried at one end thereof on the inner seat surface 9. In this case, the outer valve spring 10 has a relatively large preset load, while the inner valve spring 11 has a relatively small preset load. In Figure, the reference numeral 12 is a rocker arm, and the numeral 13 is cam shaft.
The valve spring retainer 4 will be described below in detail.
First, for a quenched and solidified aluminum alloy powder for forming a matrix to make a material for the valve spring retainer 4, a powder was produced utilizing an atomizing process, which consists of 14.5% by weight of Si, 2.5% by weight of Cu, 0.5% by weight of Mg, 4.5% by weight of Fe, 2.0% by weight of Mn, and the balance of Al including unavoidable impurities.
Grains of Al₂O₃, SiC, Si₃N₄, ZrO₂, SiO₂, TiO₂, Al₂O₃-SiO₂, and metal Si were prepared as hard grains, and a hard grain mixture was produced by selecting the following grains from these prepared grains.

Al₂O₃ grain 48.5% by weight

ZrO₂ grain 30.2% by weight

SiO₂ grain 20.0% by weight

TiO₂ grain 1.3% by weight
Aluminum alloys a₁ to a₃ having area rates of the hard grain mixture given in Table 1 were produced by blending the hard grain mixture with the aluminum alloy powder through individual steps which will be described hereinbelow.
The aluminum alloy powder and the hard grain mixture were blended in a V-shaped blender, and the individual blended powders were then subjected to a cold isostatic pressing process (CIP process) to provide powder compacts. Then, the individual powder compacts were placed into a uniform heat oven and left therein for a predetermined time. Thereafter, they were subjected to a hot extrusion to provide the aluminum alloys a₁ to a₃ each formed into a rounded bar and having a diameter of 20.5 mm and a length of 400 mm.
Each of these aluminum alloys a₁ to a₃ is used for a material for the valve spring retainer according to the present invention, and the above-described diameter thereof is substantially equal to that of the base portion 5.
For comparison, alloys b₁ and b₂ of Comparative Example having area rates of hard grain mixture given in Table I were produced by blending the hard grain mixture with an aluminum alloy of the same composition as described above and through the same steps as the above-described steps. Table I

Aluminum alloy Area rate (%) Ratio of area rates

a₁

1 1.1

a₂ 3 1.5

a₃ 8 1.4

b₁ 0.2 1.04

b₂ 0.4 1.04
In Table I, the ratio of the area rates was determined in the following manner.
As shown in Fig.2, the flow pattern of a fiber structure of the material in the aluminum alloys a₁ to a₃, b₁ and b₂, and thus the bar-like products 14 is parallel to an extruding direction X, and if the area rate in the extruding direction X is represented by A, and the area rate in a direction Y perpendicular to the extruding direction X is by B, their ratio, i.e., A/B is the ratio of the area rates.
In this case, particles of the hard grain mixture p are arranged along the flow pattern of the fiber structure of the material and thus in the extruding direction X.
Then, the bar-like product 14 was cut into two types of first and second test pieces which were then subjected to a slide wear test to provide the results given in Table II.
The size of each test piece is 10 mm long x 10 mm wide x 5 mm thick. As shown in Fig.3A, the first test piece T1 was cut so that a square slide surface 15₁ thereof may be parallel to the extruding direction X. On the other hand, as shown in Fig.3B, the second test piece T2 was cut so that a square slide surface 15₂ thereof may be parallel to the direction Y perpendicular to the extruding direction.
The slide wear test was conducted over a sliding distance of 18 km by pressing the slide surface 15₁, 15₂ of each of the first and second test pieces T₁ and T₂, with a pressure of 200 kg/cm², onto a disc of a silicon-chromium steel (JIS SWOSC-carburized material) with a diameter of 135 mm which is rotatable at a rate of 2.5 m/sec., while dropping a lubricating oil under a condition of 5 cc/min. The worn amount was measured by determining a difference (»m) in thickness for the first and second test pieces T1 and T2 before and after the test. It is to be noted that the silicon-chromium steel is used as a material for forming the valve spring. Table II

Aluminum alloy Amount of Wear (»m)

First test piece T₁ Second test piece T₂

a₁ 0.5 0.8

a₂ 0.4 0.7

a₃ 0.2 0.4

b₁ 12.0 12.2

b₂ 5.0 5.4
It is apparent from Table II that for the aluminum alloys a₁ to a₃, because the particles of the hard grain mixture are arranged along the flow pattern of the material in the slide surface 15₁ of the first test piece T1, the area rate of the hard grain mixture on that slide surface 15₁ is higher than that on the slide surface 15₂ of the second test piece T2. Therefore, the wear resistance of the slide surface 15₁ of the first test piece T1 is improved as compared with the slide surface 15₂ of the second test piece 15₂.
For the alloys b₁ and b₂ of Comparative Examples, because the area rates of the hard grain mixture are lower on the slide surfaces 15₁ and 15₂ of the first and second test pieces T1 and T2, the worn amount of the test pieces are larger. In addition, because the ratios of the area rates thereof are smaller, there is little difference in worn amount between both the slide surfaces 15₁ and 15₂.
On the basis of the results of the slide wear test, a flow pattern f₁ of the fiber structure of the material in a surface layer region r1 having the outer seat surface 8 in the valve spring retainer 4 according to the present invention, as clearly shown in Fig.4A. In addition, the flow pattern f₁ in the surface layer region r₁ is continuous with a flow pattern f₂ of the fiber structure along an axis of the material in a surface region r₂ of the base portion 5. Therefore, the inner seat surface 9 is formed into a surface perpendicular to the flow pattern f₂. In Figures 4(A), 4(B) and 7, the reference numeral 16 is a mounting hole for the valve stem passing through the flange portion 6, the base portion 5 and the projection 7. An inner peripheral surface of the mounting hole 15 is formed into a tapered surface convergent toward the outer end face 7a of the projection 7 from the outer end face 6a of the flange portion 6.
A valve spring retainer 4 as described above may be produced through the following steps.
The bar-like product 14 shown in Fig.2 is sliced as shown by a dashed life to provide a disk-like billet 17 having a thickness of 7 mm as shown in Fig.5A. Thus, a flow pattern of the fiber structure along the axis of the material as with the flow pattern f₂ exists in this billet 7.
As shown in Fig.5B, the billet 17 is placed onto a base portion shaping region R2 of a lower die 19 in a closed forging apparatus 18. The reference character 20₁ is a first upper die having a tapered pressing projection 21₁.
As shown in Fig.5C, the billet 17 is pressed by the first upper die 20 , so that a lower side of the billet 17 is expanded into a projection shaping region R3 of the lower die 19 and at the same time, an upper side of the billet 17 is widened into a flange shaping region R1 to provide a primary formed product F1. This widening action causes the material to flow radially as indicated by an arrow c, thereby providing a flow pattern f₁ as described above.
As shown in Fig.5D, the primary formed product F1 is pressed by a second upper die 20₂ having a tapered pressing projection 21₂ longer than the pressing projection 21₁ of the first upper die 20₁, so that a lower portion of the primary formed product F1 is filled into the projection shaping region R3 to provide a projection 7. In addition, an upper portion of the primary formed product F1 is filled into the flange shaping region R1 to provide a flange portion 6. Further, a mounting hole 16 is shaped by the pressing projection 21₂, thus providing a secondary formed product F2. Even at this flange portion 6 shaping step, a similar widening action is performed.
As shown in Fig.5E, the secondary formed product F2 is punched by a punch 23 having a punching projection 22 longer than the pressing projection 21₂ of the second upper die 20₂, so that the mounting hole 16 is penetrated, thereby providing a valve spring retainer 4.
Table III illustrates results of a actual durability test conducted for 100 hours for the valve spring retainers made in the same technique as described above using the aforesaid aluminum alloys a₁ to a₃, b₁ and b₂. In Table III, the valve spring retainers a₁ to a₃, b₁ and b₂ were made from the aluminum alloys a₁ to a₃, b₁ and b₂, respectively. Hence, the valve spring retainers a₁ to a₃ correspond to the present invention, and the valve spring retainers b₁ and b₂ correspond to Comparative Examples. In the above test, the ratio of slide surface pressures on the outer and inner seat surfaces 8 and 9 by the load distribution between the outer and inner valve springs 10 and 11 was set such that outer seat surface 8 ratio to inner seat surface 9 = 1.8 : 1.
The amount of wear was measured by determining a difference (»m) between the thicknesses t₁ and t₂ of the outer and inner seat surfaces 8 and 9 before and after the test (Fig.4A). Table III

Valve spring retainer amount of wear (»m)

Outer seat surface Inner seat surface

Present invention

a₁ 28 25

a₂ 20 19

a₃ 10 11

Comparative Example

b₁ 450 120

b₂ 300 95
It can be seen from Table III that in the valve spring retainers a₁ to a₃ according to the present invention, the difference in the amount of wear between the outer and inner seat surfaces 8 and 9 is slight and consequently, it is possible to suppress the variation in load distribution of the outer and inner valve springs 10 and 11 to the utmost. This is attributable to the fact that the flow pattern f₁ of the fiber structure of the material in the surface layer region r₁ having the outer seat surface 8 has been formed as described above to improve the outer seat surface 8 and to the fact that the above-described ratios of the area rates possessed by the aforesaid aluminum alloys a₁ to a₃ have been substantially established.
For the purpose of conducting a fatigue test, a bar-like product 14₁ having a diameter of 35 mm and as shown in Fig.6 was produced as a comparative example in the same manner as described above, and subjected to cutting operations to fabricate a valve retainer 4₁ with its axis aligned with the extruding direction X. In this valve spring retainer 4₁, a flow pattern f₃ of the fiber structure of the material is all in an axial direction as shown in Fig.4B.
For the valve spring retainer 4 according to the present invention, the aforesaid present invention a₂ was used.
The area rates and the ratio a/b of the area rates of the hard grain mixture on the outer and inner seat surfaces 8 and 9 of the present invention a₂ and the comparative example are as given in Table IV. Here, in the ratio a/b of the area rates, a corresponds to the area rate on the outer seat surface 8, and b corresponds to the area rate on the inner seat surface. Table IV

Present invention a₂ Comparative example

OSS ISS OSS ISS

Area rate (%) 3.6 2.4 3.02 2.99

Ratio of area rates (a/b) 1.5 1.0

OSS = Outer seat surface ISS = Inner seat surface
Each of the valve spring retainers 4 and 4₁ was secured to the valve stem 3 of the intake valve 2, and a tensile-tensile fatigue test was conducted with one of jigs engaged with the valve face 2a and the other jig engaged with the outer seat surface 8 to determine the fatigue strength of the junction d (Fig.4A) between the flange portion 6 and the projection 7 in each of the valve spring retainers 4 and 4₁, thereby providing results given in Table V.
The fatigue strength is represented by a load at a repeated-loading number of 10⁷ to the fracture and at a fracture probability of 10%. Table V

Fatigue strength (kg)

Present invention a₂ 600

Comparative example 480
As can be seen from Table V, the present invention a₂ is improved in fatigue strength, as compared with the comparative example. This is attributable to the fact that the flow patterns f₁ and f₂ of the fiber structure of the material are continuous as described above.
The ratio a/b of the area rate a of the hard grain particles on the outer seat surface to the area rate b of the hard grain particles on the inner seat surface may be set such that 1.05 ≦ a/b ≦ 1.50.
By increasing the area rate of the hard grain particles on the outer seat surface in this way and by setting such area rate and the area rate of the hard grain particles on the inner seat surface into a particular relationship, it is possible to moderate the difference in amount of wear between the outer and inner seat surfaces as described above. If the ratio a/b < 1.05, the resulting valve spring retainer will have no difference in worn amount between the outer and inner seat surfaces and hence, cannot serve a practical use. On the other hand, if a/b > 1.50, the resulting valve spring retainer will have a lower strength and likewise cannot serve a practical use.
Fig.7 illustrates another embodiment of a valve spring retainer made in a manner similar to that described above. In this valve spring retainer 4, when the axial length is L1 between the outer end face 6a of the flange portion 6 and the outer end face 7a of the projection 7, and the axial length is L2 between the outer end face 6a of the flange portion 6 and the inner seat surface 9, L2 > 1/2 L1. In addition, when axial length is L3 between the outer seat surface 8 and the inner seat surface 9; the axial length is L4 between the outer end face 6a of the flange portion 6 and the outer seat surface 8, and the axial length is L5 between the outer end face 7a of the projection 7 and the inner seat surface 9, L3 > L4, and L3 > L5.
In the present embodiment, L1 = 8.8 mm; L2 = 6.0 mm; L3 = 3.8 mm; L4 = 2.2 mm; and L5 = 2.8 mm. The outside diameter of the outer end face 6a of the flange 6 and thus the outer seat surface 8 is 28.0 mm; the outside diameter of the outer end face 7a of the projection 7 is 15.4 mm; and the outside diameter of the inner seat surface 9 is 21.7 mm.
With such a construction the wall thickness of the base portion 5 is increased and hence, it is possible to improve the rigidity of the entire valve spring retainer 4.
The outer peripheral surfaces of both the base portion 5 and the projection 7 are formed into tapered surfaces convergent toward the outer end face 7a of the projection 7, wherein the tapered angle is set at 5° in each case.
If the valve spring retainer is constrcuted in such a manner, not only the continuity of the internal crystal is improved as compared with a construction in which the both outer peripheral surfaces are perpendicular to the outer and inner seat surfaces 8 and 9, but also the spraying of a lubricating oil flying from the shaft end side of the valve stem 3 is facilitated, and there is also an effect of suppressing the thermal deformation of the valve spring retainer 4. Further, it is possible to prevent the individual valve springs 10 and 11 from abutting against the outer peripheral surfaces.
In a mounting hole 16 for the valve stem, a rounded portion 16a is provided around the entire periphery of an edge of an opening located in the outer end face of the projection. The rounded portion 16a is formed by machining and has a curvature radius of 1.5 mm.
If the valve spring reatiner is constructed in this manner, a flash will not remain at the opening edge, and it is also possible to avoid the concentration of stress. In order to obtain this effect, the curvature radius may be more than 1.5 mm.
A second example of a material for the valve spring retainer will be described below.
For a quenched and solidified aluminum alloy powder for forming a matrix, a powder was produced utilizing an atomizing process, which consists of 14.5% by weight of Si, 2.5% by weight of Cu, 0.6% by weight of Mg, 4.6% by weight of Fe, 2.1% by weight of Mn, and the balance of Al including unavoidable impurities.
Grains similar to those previously described were prepared as hard grains, and a hard grain mixture was produced by selecting the following grains from these prepared grains.

Al₂O₃ grain 48.5% by weight

ZrO₂ grain 30.2% by weight

SiO₂ grain 20.0% by weight

TiO₂ grain 1.3% by weight
Aluminum alloys a₄ and a₅ having area rates of the hard grain mixture given in Table VI were produced by blending the hard grain mixture in added amounts given in Table VI to the aluminum alloy powder and through individual steps which will be described hereinbelow.
The aluminum alloy powder and the hard grain mixture were blended in a V-shaped blender, and the individual blended powders were then subjected to a cold isostatic pressing process (CIP process) to provide powder compacts. Then, the individual powder compacts were placed into a uniform heat oven and left therein for a predetermined time. Thereafter, they were subjected to a hot extrusion to provide the aluminum alloys a₄ and a₅ each formed into a rounded bar and having a diameter of 35 mm and a length of 800 mm. Table VI

Alluminum alloy Hard grain mixture

Added amount (% by weight) Area rate (%)

a₄ 0.7 1.0

a₅ 3.0 4.5
For comparison, comparative alloys b₃ and b₄ having area rates of hard grain mixture given in Table VII were produced by blending the hard grain mixture in added amounts in Table VII to an aluminum alloy of the same composition as described above and through the same steps as the above-described steps. Table VII

Comparative alloy Hard grain mixture

Added amount (% by weight) Area rate (%)

b₃ 0.07 0.1

b₄ 6.7 10.0
The aluminum alloys a₄ and a₅ and the comparative alloys b₃ and b₄ were cut into test pieces which were then subjected to a slide wear test to provide results given in Table VIII.
The slide wear test was conducted over a sliding distance of 18 km by pressing the test pieces 10mm long x 10mm wide x 5 mm thick with a pressure of 200 kg/cm² onto a disc of a chromium-vanadium steel (JIS SWOCV) with a diameter of 135 mm which is rotatable at a rate of 2.5 m/sec., while dropping a lubricating oil under a condition of 5 cc/min. The amount of wear was measured by determining a difference (g) in weight for the test pieces and the disc before and after the test. It is to be noted that the chromium-vanadium steel is used as a material for forming the valve spring. Table VIII

Aluminum alloy amount of wear (g)

a₄ 0.0009

a₅ 0.0004

Comparative Example

b₃ 0.01

b₄ 0.0001
It is apparent from Table VIII that each of the aluminum alloys a₄ and a₅ has an excellent wear resistance. In addition, it was confirmed hat the amount of disc wear was suppressed to 0.0002 g in a combination with the aluminum alloy a₄ and to 0.0003 g in a combination with the aluminum alloy a₅. This makes it clear that the aluminum alloys a₄ and a₅ exhibit an excellent slide characteristic in a combination with the valve spring. On the other hand, the alloy b₃ of the Comparative Examples was increased in amount of wear because of a smaller added amount of the hard ggrain mixture and a lower area rate The comparative example alloy a₄ had a good wear resistance because of a larger added amount and a higher area rate, but the mating disc wear was increased and the amount of disc wear was 0.0007 g.
As described above, the aluminum alloys a₄ and a₅ exhibit an excellent slide characteristic in a combination with a steel, but in this case, it is desirable that the hardness of the steel is Hv 400 or more. If the hardness of the steel is less than Hv 400, the amount of steel wear will be increased.
A stress corrosion and cracking test (JIS H8711) was carried out for the individual test pieces to provide results given in Table IX.
The stress corrosion and cracking test was conducted by immersing each of test pieces 100 mm long x 20 wide x 3 mm thick with a loaded stress thereon of σ_0.2 x 0.9 (σ_0.2 being a 0.2% load-carrying capacity of each alloy) into an aqueous solution of NaCl having a concentration of 3.5% and a liquid temperature of 30°C for 28 days. The superiority or inferiority of the resistance to stress corrosion and cracking was judged by the presence or absence of cracks generated in the test piece. Table IX

Aluminum alloy Presence or absence of cracks

a₄ absence

a₅ absence

Alloy of Comparative Example

b₃ absence

b₄ presence
As apparent from Table IX, the aluminum alloys a₄ and a₅ and the alloy b₃ of the Comparative Examples each have an excellent resistance to stress corrosion and cracking. The alloy b₄ of Comparative Examples has a deteriorated resistance to stress corrosion and cracking, because of a higher area rate of the hard grain mixture thereof.
Further, a compression-tensile fatigue test was repeated 10⁷ runs for every test piece at a temperature of 150°C to provide results given in Fig.X. Table X

Aluminum alloy Fatigue limit (kg/mm²)

a₄ 17.2

a₅ 17.0

Alloy of Comparative Example

b₃ 16.8

b₄ 12.1
It can be seen from Table X that the aluminum alloys a₄ and a₅ and the alloy b₃ of the Comparative Examples each have a relatively large fatigue strength. The alloy b₄ of the Comparative Examples has a smaller fatigue strength, because of a higher area rate of the hard grain mixture thereof.
It is apparent from the aforesaid individual tests that the aluminum alloys a₄ and a₅ are excellent in resistances to wear and to stress corrosion and cracking and each has a relatively large fatigue strength.
Therefore, the aluminum alloys a₄ and a₅ are most suitable for use as a material for forming a machanical structural member used at a high temperature under a high surface pressure and under a rapid sliding movement, e.g., a slide member for an internal combustion engine, and particularly, a material for forming a spring retainer used in a valve operating system.
Fig.8 illustrates a relationship among the added amount and area rate of the hard grains, the average grain size of tjhe hard grains, and the natures of a valve spring retainer and a valve spring, when the valve spring retainer is formed of the aluminum alloy. In a combination of the valve spring retainer and the valve spring, an optimal range is a region indicated by G in Fig.8.
A third example of a material for the valve spring retainer will be described below.
An aluminum alloy for this material is comprised of a matrix formed of a quenched and solidified aluminum alloy powder, and hard grains dispersed in the matrix. The hard grains used are similar to those described above. The average grain size D (in microns, weight average) of the hard grains is set such that 3 »m ≦ D ≦ 30 »m, and the added amount L (in weight %) is set such that 0.5% by weight ≦ L ≦ 20% by weight.
Further, the hardness Hv of the hard grains is set such that 700 ≦ Hv ≦ 3,000, and when $K = (L + 0.5)(D - 1)$

in this range of the hardness, 200 < K ≦ 600 when 700 ≦ Hv < 1,000; 80 < K ≦ 200, when 1,000 ≦ Hv < 1,500; 35 < K ≦ 80 when 11500 ≦ Hv < 2,000; and 13 ≦ K ≦ 35 when 2,000 ≦ Hv ≦ 3,000.
In this case, if the average grain size D of the hard grains is smaller than 3 »m, the wear resistance of the matrix is lower. On the other hand, if D > 30 »m, the fatigue strength of the matrix will be reduced, and the wearing of the valve spring will be increased, resulting in a valve spring retainer that cannot be put into practical use.
Further, if the added amount L of the hard grains is smaller than 0.5% by weight, the wear resistance of the matrix also will not be improved. On the other hand, if L > 20% by weight, the fatigue strength of the matrix will also be reduced, and the wearing of the valve spring will be increased, resulting in a valve spring retainer that cannot be put into practical use.
Yet further, if the hardness Hv of the hard grains is smaller than 700 or if Hv > 3,000, the intended slide characteristics cannot be obtained.
In this case, in 700 ≦ Hv < 1,000, the wearing of the matrix will be increased when K ≦ 200, on the one hand, and the wearing of the valve spring will be increased when K > 600, on the other hand.
In 1,000 ≦ Hv < 1,500, the wearing of the matrix also will be increased when K ≦ 80, on the one hand, and the wearing of the valve spring also will be increased when K > 200, on the other hand.
Further, in 1,500 ≦ Hv < 2,000, the wearing of the matrix also will be increased when K ≦ 35, on the one hand, and the wearing of the valve spring also will be increased when K > 80, on the other hand.
Yet Further, in 2,000 ≦ Hv ≦ 3,000, the wearing of the matrix also will be increased when K < 13, on the one hand, and the wearing of the valve spring also will be likewise increased when K > 35, on the other hand.
Fig.9 illustrates a relationship between the average grain size and the added amount of the hard grains in the aforesaid range of the hardness Hv of the hard grains. In Fig.9, a range surrounded by oblique lines is for the material used in the present invention.
Specified examples will be described below.
For a quenched and solidified aluminum alloy powder, a powder consisting of 14.5% by weight of Si, 2.5% by weight of Cu, 0.5% by weight of Mg, 4.5% by weight of Fe, 2.0% by weight of Mn, and the balance of Al including unavoidable impurities was produced utilizing an atomizing process.
Aluminum alloys a₆ to a₁₅ were produced by blending hard grains having various average grain sizes in added amounts given in Table XI to the aluminum alloy powder according to Fig.9 and through steps which will be described below.

The aluminum allow powder and the hard grains were blended in a V-shaped blender and then, the resulting powder mixture was subjected to a cold isostatic pressing process (CIP process) to provide a powder compact which was then placed into a uniform heat oven and left therein for a predetermined time. Thereafter, the powder compact was subjected to a hot extrusion, thus providing the aluminum alloys a₆ to a₁₅ formed into a rounded bar having a diameter of 35 mm and a length of 400 mm.

Table XI

Aluminum alloy	Hard grains
	Al₂O₃ Hv 2,500		Al₂O₃ SiO₂ Hv 1,100		Metal Si Hv 800		K
	AGS (»m)	AA (%)	AGS (»m)	AA (%)	AGS (»m)	AA (%)
a₆	3	15	-	-	-	-	31
a₇	5	4	-	-	-	-	18
a₈	7	2	-	-	-	-	15
a₉	15	0.5	-	-	-	-	14
a₁₀	30	0.5	-	-	-	-	29
a₁₁	-	-	10	15	-	-	139.5
a₁₂	-	-	20	7	-	-	142.5
a₁₃	-	-	30	6	-	-	188.5
a₁₄	-	-	-	-	22	20	430.5
a₁₅	-	-	-	-	29	16	462
AGS = Average grain size AA (%) = Added amount (% by weight)

For comparison, alloys b₅ to b₁₁ of the Comparative Examples were produced by blending hard grains having various average grain sizes in added amounts given in Table XII to an aluminum alloy of the same composition as described above and through the same steps as descrived above. The alloy b₁₂ of the Comparative Examples contains no hard grains and comprises only the aluminum alloy matrix.

Table XII

Comparative alloy	Hard grains
	Al₂O₃ Hv 2,500		Al₂O₃ SiO₂ Hv 1,100		Metal Si Hv 800		K
	AGS(»m)	AA (%)	AGS (»m)	AA (%)	AGS (»m)	AA (%)
b₅	2.5	0.2	-	-	-	-	1.05
b₆	20	20	-	-	-	-	430.5
b₇	50	25	-	-	-	-	1249.5
b₈	-	-	3	1	-	-	3
b₉	-	-	40	25	-	-	994.5
b₁₀	-	-	-	-	5	1	6
b₁₁	-	-	-	-	60	25	1504.5
b₁₂	-	-	-	-	-	-	-
AGS = Average grain size AA (%) = Added amount (% by weight)

The aluminum alloys a₆ to a₁₅ and the comparative alloys b₅ to b₁₂ were cut into test pieces which were then subjected to a slide wear test to provide results given in Tables XIII and XIV.

The slide wear test was conducted over a slide distance of 18 km by pressing the test piece 10mm long x 10 mm wide x 5 mm thick with a pressure of 200 kg/cm² onto a disc of a silicon-chromium steel (JIS SWOSC-carburized material) with a diameter of 135 mm which is rotatable at a rate of 2.5 m/sec., while dropping a lubricating oil under a condition of 5 cc/min. The amount of wear was measured by determining a difference (»m) in thickness for the test piece and the disc before and after the test.

Table XIII

Aluminum alloy	Amount of wear (»m)
	Test piece	Disc
a₆	0.5	0.5
a₇	0.4	0.4
a₈	0.5	0.5
a₉	0.5	0.6
a₁₀	0.6	0.6
a₁₁	0.5	0.5
a₁₂	0.5	0.4
a₁₃	0.4	0.4
a₁₄	0.5	0.5
a₁₅	0.5	0.5

Table XIV

Comparative alloy	Amount of wear (»m)
	Test piece	Disc
b₅
	12	≦ 0.1
b₆	≦ 0.1	15.0
b₇	≦ 0.1	55
b₈	20	≦ 0.1
b₉	0.2	11.0
b₁₀	40	≦ 0.1
b₁₁	0.2	4.5
b₁₂	2,500	≦ 0.1

As apparent from Tables XIII and XIV, the aluminum alloys a₆ to a₁₅ are smaller in amount of wear as compared with the comparative alloys b₅ to b₁₂ and exhibit an excellent slide characteristic for suppressing the wearing of the disc which is a mating steel member. This is attributable to the fact that the hardness, the grain size and the added amount of the hard grains dispersed in the matrix was set to proper values as described above.
Using the aluminum alloys a₆, a₈, a₁₀, a₁₂, a₁₄ and a₁₅ and the comparative alloys b₅, b₇, b₈, b₁₀ and b₁₂, valve spring retainers were produced in a manner similar to that described above and subjected to an actual durability test to determine the amount of wear of the valve spring retainers 4 and outer valve springs 10, thereby providing results given in Tables XV and XVI.
The amount of wear was measured by determining the difference (»m) in thickness of the flange portions of the valve spring retainers and ends of the outer valve spring before and after the test. The outer valve spring is formed of a silicon-chromium (JIS SWOSC-V). Table XV

Aluminum alloy Amount of wear (»m)

Valve spring retainer Outer valve spring

a₆

20 19

a₈ 18 18

a₁₀ 21 21

a₁₂ 19 20

a₁₄ 19 19

a₁₅ 21 20

Table XVI

Comparative alloy Amount of wear (»m)

Valve spring retainer Outer valve spring

b₅ 105 4

b₇ 2 450

b₈ 210 12

a₁₀ 370 ≦ 1

a₁₂ Flange portion worn ≦ 1
As apparent from Tables XV and XVI, the valve spring retainers made using the aluminum alloys a₆ and a₈ are smaller in amount of wear and exhibit an excellent slide characteristic for suppressing the wearing of the outer valve springs. On the contrary, the valve spring retainers made using the comparative alloys b₅ and b₇ are either too high in wear resistance to cause an increased amount of wear of the outer valve spring, or too low in wear resistance to lead to an increased amount of wear of the valve spring retainers themselves
Consequently, the slide characteristic is degraded.
A fourth example of a material for the valve spring retainer will be described below.
The production of a high strength aluminum alloy as the material was conducted by the preparation of a powder, the formation of a powder compact and the hot forging thereof.
An atomizing process was used for the preparation of the powder. The prepared powder was subjected to a screening treatment, wherein a powder whose particles have a diameter smaller than 100 mesh was collected for use.
At least one hydride-forming component selected from the group consisting of Ti, Zr, Co, Pd and Ni may be added to a molten metal for preparing the powder, or to the prepared powder. To facilitate the formation of a hydride, the latter is preferred.
If necessary, the above-described hard grains may be added to the powder.
The formation of the powder compact includes a primary forming step and a secondary forming step.
The primary forming step is conducted under a forming pressure of 1 to 10 tons/cm² and at a powder temperature of 300°C or less, preferably 100°C to 200°C. In this case, if the powder temperature is lower than 100°C, the density of the powder compact will not be increased. On the other hand, if the powder temperature is higher than 200°C, it is feared that a bridging of the powder may be produced, resulting in a reduced operating efficiency.
The density of the powder compact may be set at 75% or more. Any density lower than this value will result in a degraded handleability.
The secondary forming step is conducted under a forming pressure of 3 to 10 tons/cm², at a powder compact temperature of 420°C to 480°C and at a mold temperature of 300°C or less, preferably 150°C to 250°C. In this case, if the mold temperature is lower than 150°C, the density of the powder compact will not be increased. On the other hand, if the mold temperature is higher than 250°C, the lubrication between the mold and the powder compact is difficult, resulting in a fear of seizing of the powder compact.
The density of the powder compact is preferably set in a range of 95% to 100%. If the density is lower than this value, the aluminum alloy will crack in the hot forging step.
It should be noted that in forming the powder compact, only the primary forming step may be used in some cases.
The hot forging may be conducted at a powder compact heating temperature of 350°C to 500°C. In this case, if the heating temperature is lower than 350°C, the aluminum alloy will crack. On the other hand, it the heating temperature is higher than 500°C, a blister will be produced in the aluminum alloy.
The alumninum alloy is most suitable ont only as a material for forming the valve spring retainer, but also as a material for forming other slide members for an internal combustion engine, and may be used, for example, for a cap for bearing members such as a connecting rod, and a bearing cap for a crank journal.

Specified examples will be described below.

Table XVII

Aluminum alloy	Chemical constituents (% by weight)
	Si	Cu	Mg	Fe	Mn	Ti	Zr	Co	Pd	Ni
a₁₆	18	2.2	0.7	4.2	2.1	2.0	-	-	-	-
a₁₇	18	2.1	0.6	4.0	1.9	-	2.2	-	-	-
a₁₈	17	1.6	0.4	3.8	1.7	-	-	1.3	-	-
a₁₉	16	2.5	0.5	3.9	1.8	-	-	-	1.5	-
a₂₀	17	1.8	0.3	4.2	1.8	-	-	-	-	1.2
a₂₁	17	2.1	0.5	4.0	2.0	1.0	-	-	-	-
a₂₂	18	2.0	0.6	4.0	1.8	3.6	-	-	-	-
a₂₃	14.5	2.2	0.6	4.2	2.1	1.2	-	-	-	-

Comparative example
b₁₃
	17	2.5	0.5	3.9	1.8	-	-	-	-	-
b₁₄	16	2.2	0.8	4.3	2.2	-	-	-	-	-

Using a molten aluminum alloy containing chemical constituents given in Table XVII, a powder was prepared utilizing an atomizing process and then subjected to a screening to provide a powder having a diameter smaller than 100 meshes of its particles.
The above powder was used to produce a short columnar powder compact having a diameter 60 mm and a height of 40 mm. In this case, the primary forming step was conducted under a forming pressure of 7 tons/cm² and at a powder temperature of 120°C, and the density of the resulting powder compact was 80%. The secondary forming step was conducted under a forming pressure of 9 tons/cm², at a powder compact temperature of 460°C and at a mold temperature of 240°C, and the density of the resulting powder compact was 99%.
The powder compacts corresponding to the aluminum alloys a₁₆ to a₂₂ and the comparative alloy b₁₃ were subjected to a hot forging to provide these alloys. The hot forging was conducted under free forging conditions until a powder compact heating temperature of 480°C, a mold temperature of 150°C and a height of 20 mm were reached.
In addition, the powder compact corresponding to the comparative alloy b₁₄ was subjected to a degassing treatment and to a hot extrusion to provide that alloy.
The aluminum alloys a₁₆ to a₂₃ and the comparative alloys b₁₃ and b₁₄ were cut into test pieces having a diameter of 5 mm and a length of 20 mm at their parallel portions. Using these test pieces, a compression-tensile fatigue test was repeated 10⁷ runs at a test temperature of 200°C. In addition, for each test piece, a melt gas carrier process was utilized to measure the amount of hydrogen gas.

Table XVIII gives results of the fatigue test and results of the measurement of the amount of hydrogen gas.

Table XVIII

Aluminum alloy	Fatigue limit (Kg/mm²)	Amount of hydrogen gas (cc/100g alloy)
a₁₆	14.5	8
a₁₇	14.2	10
a₁₈	14.5	11
a₁₉	14.0	9
a₂₀	14.5	10
a₂₁	14.8	11
a₂₂	14.2	12
a₂₃	14.6	11

Comparative alloy
b₁₃	9.5	12
b₁₄	15.0	2

As apparent from Table XVIII, each of the aluminum alloys a₁₆ to a₂₃ has a relative large fatigue strength in spite of a larger content of hydrogen gas. This is due to the fact that the hydrogen gas in the alloys react with Ti, Zr, Co, Pd or Ni and is thus fixed in the form of a hydride.
The comparative alloy b₁₃ has a fatigue strength reduced due to the presence of hydrogen gas, because of the absence of any hydride forming constituents such as Ti and like.
The comparative alloy b₁₄ has been provided through the degassing treatment and hence, of course, has a reduced hydrogen gas content and consequently has an improved fatigue strength.
To conduct various tests which will be described hereinbelow, comparative alloys b₁₅ and b₁₆ having aluminum alloy compositions given in Table XIX were produced. The producing method was the same as for the aluminum alloys a₁₆ to a₂₃. The composition of the comparative example b₁₅ corresponds to JIS AC8C which is a forging material. Table XIX

Comparative alloy Chemical constituents (% by weight)

Si Cu Mg Fe Mn

b₁₅ 9.2 3.2 1.0 < 1.0 < 0.5

b₁₆ 20.0 3.5 1.5 5.0 -

Table XX gives the thermal expansion coefficient and Young's modulus of the aluminum alloys a₁₆ to a₂₃ and the comparative alloy b₁₅.

Table XX

Aluminum alloy	Thermal expansion coefficient (x 10⁻⁶, 20 to 200°C)	Young's modulus (200°C, Kg/mm²)
a₁₆	18.0	9,200
a₁₇	18.2	9,100
a₁₈	18.6	9,000
a₁₉	18.4	9,300
a₂₀	18.4	9,400
a₂₁	18.2	9,300
a₂₂	17.8	9,500
a₂₃	18.4	9,300

Comparative alloy
b₁₅	20.5	7,000

It can be seen from Table XX that the aluminum alloys a₁₆ to a₂₃ are reduced in thermal expansion coefficient and improved in Young's modulus as compared with the comparative example b₁₅. This is primarily attributable to the content of Fe.
Table XXI gives results of a stress corrosion and crack test (JIS H8711) for the aluminum alloys a₁₆ to a₂₃ and the comparative alloy b₁₆.
The stress corrosion and crack test was conducted by immersing test pieces 10 mm long x 20 mm wide x 3 mm thick with a load stress thereon of σ_0.2 x 0.9 (σ_0.2 being a 0.2% load carrying ability of each alloy) in a 3.5% aqueous solution of NaCl at a liquid temperature of 30°C for 28 days, and the superiority or inferiority of the stress corrosion and crack resistance was judged by the presence or absence of cracks generated in the test pieces. Table XXI

Aluminum alloy Presence or absence of cracks

a₁₆ Absence

a₁₇ Absence

a₁₈ Absence

a₁₉ Absence

a₂₀ Absence

a₂₁ Absence

a₂₂ Absence

a₂₃ Absence

Comparative alloy

b₁₆ Presence
It can be seen from Table XXI that the aluminum alloys a₁₆ to a₂₃ are excellent in stress corrosion and crack resistance, as compared with the comparative alloy b₁₆. This is primarily attributable to the addition of Mn.
Table XXII gives results of a slide wear test for the aluminum alloys a₁₆, a₁₇ and a₁₈ and the comparative alloy b₁₅.
The slide wear test was conducted over a sliding distance of 18 km by pressing the test pieces 10 mm long x 10 mm wide x 5 mm thick, with a pressure of 200 kg/cm², onto a disc of a carbon steel for a mechanical structure (JIS S50C) with a diameter of 135 mm which is rotatable at a rate of 2.5 m/sec., while dropping a lubricating oil under a condition of 5 cc/min. The amount of wear was measured by determining a difference (g) in weight of the test pieces before and after the test. Table XXII

Aluminum alloy Amount of wear (g)

a₁₆ 0.0025

a₁₇ 0.0028

a₁₈ 0.0040

Comparative alloy

b₁₅ 0.06
As is apparent from Table XXII, each of the aluminum alloys a₁₆, a₁₇ and a₁₈ has an excellent wear resistance, as compared with the comparative alloy b₁₅. This is attributable to the content of Si.
Aluminum alloys a₂₄ to a₂₉ containing hard grains will be described below.

Chemical constituents of aluminum alloy matrices in the aluminum alloys a₂₄ to a₂₉ are indentical with the aforesaid aluminum alloys a₁₆ to a₂₁ given in Table XVII. Various hard grains as given in Table XXIII were dispersed in these matrices. The aluminum alloys a₂₄ to a₂₉ were produced in the same manner as for the aforesaid aluminum alloys a₁₆ to a₂₃.

Table XXIII

Aluminum alloy	Hard grains (% by weight)
	Al₂O₃	SiC	Si₃N₄	ZrO₂	Metal Si	TiO₂
a₂₄	3	-	-	-	-	-
a₂₅	-	2	-	-	-	-
a₂₆	-	-	3	-	-	-
a₂₇	-	-	-	2	-	-
a₂₈	-	-	-	-	4	-
a₂₉	-	-	-	-	-	3

Table XXIV gives results of the fatigue test for the aluminum alloys a₂₄ to a₂₉ and results of the measurement of the hydrogen content therein. The procedures for the test and the measurement are the same as described above. Table XXIV

Aluminum alloy Fatigue limit (Kg/cm²) Hydrogen gas content (cc/100g of alloy)

a₂₄ 15.0 8

a₂₅ 15.2 10

a₂₆ 15.0 11

a₂₇ 14.5 9

a₂₈ 15.0 10

a₂₉ 15.2 8
As apparent from Table XXIV, the aluminum alloys a₂₄ to a₂₉ are improved in fatigue strength with the addition of the hard grains, as compared with those in Table XVIII.

Table XXV gives the thermal expansion coefficient and Young's modulus of the aluminum alloys a₂₄ to a₂₉.

Table XXV

Aluminum alloy	Thermal expansion coefficient (x10⁻⁶, 20 to 200°C)	Young's modulus (200°C, kg/mm²)
a₂₄	17.5	10,000
a₂₅	17.8	9,700
a₂₆	18.0	10,000
a₂₇	17.9	9,600
a₂₈	17.8	9,800
a₂₉	17.9	9,600

As is apparent from Table XXV, the aluminum alloys a₂₄ to a₂₉ are reduced in thermal expansion coefficient and improved in Young's modulus, as compared with those in Table XX. This is attributable to the fact that the hard grains such as Al₂O₃ are dispersed.
The same stress corrosion and crack test (JIS H8711) as described above was conducted for the aluminum alloys a₂₄ to a₂₉ and as a result, cracking was not observed.
Table XXVI gives results of the slide wear test as described above was conducted for the aluminum alloys a₂₄, a₂₅ and a₂₆. Table XXVI

Aluminum alloy Amount of wear (g)

a₂₄ 0.0015

a₂₅ 0.0020

a₂₆ 0.0018
As is apparent from Table XXVI, the aluminum alloys a₂₄, a₂₅ and a₂₆ have an excellent wear resistance, as compared with those in Table XXII. This is due to the fact that the hard grains such as Al₂O₃ are dispersed.
Table XXVII gives results of a creep test for the aluminum alloys a₂₄, a₂₅ and a₂₆ and the comparative alloy b₁₃.
The creep test was conducted by applying a compression force of 12 kg/mm² to the test pieces having a diameter of 6 mm and a length of 40 mm at their parallel portion at 170°C for 100 hours. The creep shrinkage amount was measured by determining the rate (%) of the lengthes before and after the test. Table XXVII

Aluminum alloy Creep shrinkage amount (%)

a₂₄ 0.03

a₂₅ 0.02

a₂₆ 0.04

Comparative alloy

b₁₃ 0.1
As is apparent from Table XXVII, the aluminum alloys a₂₄, a₂₅ and a₂₆ are decreased in creep shrinkage amount, as compared with the comparative alloy b₁₃. This is due to the fact that the dislocation of the crystal of the aluminum alloy matrix is fixed by the dispersion of the hard grains such as Al₂O₃ in the aluminum alloy matrix.
The creep shrinkage amount of the comparative alloy b₁₄ corresponding to a casting material is 0.04%, and the creep shrinkage amount of each of the aluminum alloys a₂₄, a₂₅ and a₂₆ is substantially compared with the casting material.
Table XXVIII gives a relationship between the variation in size of a crank pin hole (a diameter of 55 mm) in a connecting rod and the temperature.
A connecting rod A has its shaft portion formed of a comparative alloy I and has its cap formed of the aluminum alloy a₂₄. A connecting rod B has its shaft portion and cap formed of the comparative alloy b₁₃. In the connecting rods A and B, the caps are fastened on the side of the shaft portion by a bolt. Table XXVIII

Connecting rod Amount of variation in diameter of crank pin hole (»m)

Room temperature 150°C

A 0 + 72

B 0 + 67
As is apparent from Table XXVIII, the connecting rod A having the cap formed of the aluminum alloy a₂₄ is smaller in amount of variation in diameter of the crank pin hole with an increase of the temperature, as compared with the connecting rod formed of the comparative alloy b₁₃. This makes it possible to suppress the variation in clearance between the crank pin and the crank pin hole during operation of the engine. This is attributable to the fact that the reduction of the thermal expansion coefficient has been provided by dispersing 3% by weight of the Al₂O₃ grain in the aluminum alloy matrix.

Table XXIX gives chemical constituents of aluminum alloys a₃₀ to a₄₃, and Table XXX gives results of a fatigue test for these alloys a₃₀ to a₄₃, as well as results of a measurement of the hydrogen gas amount therein. The methods for the production of these alloys, for the fatigue test and for the measurement of the hydrogen gas amount are the same as for the above-described aluminum alloys a₁₆ to a₂₃.

Table XXIX

Aluminum alloy	Chemical constituents (% by weight)
	Si	Cu	Mg	Fe	Mn	Ti	Zr	Co	Pd	Ni
a₃₀
	14	1.2	1.0	4.5	1.6	1.0	1.0	-	-	-
a₃₁	15	2.2	0.6	3.8	1.7	1.2	-	0.6	-	-
a₃₂	17	2.5	0.4	3.5	2.2	1.0	-	-	0.4	-
a₃₃	16	2.0	0.8	4.2	1.8	1.2	-	-	-	1.2
a₃₄	14	2.0	0.6	4.0	1.5	-	0.8	0.6	-	-
a₃₅	15	1.8	0.5	3.4	2.0	-	1.0	-	0.8	-
a₃₆	15	1.7	0.4	4.0	1.6	-	1.2	-	-	0.8
a₃₇	16	2.0	0.6	3.8	1.4	-	-	1.5	0.3	-
a₃₈	15	1.8	0.8	3.6	1.6	-	-	1.4	-	0.8
a₃₉	16	2.0	0.6	4.0	0.8	-	-	-	0.4	2.0
a₄₀	15	2.2	0.4	3.5	1.0	0.6	0.4	0.4	-	-
a₄₁	15	1.8	0.4	3.3	0.8	0.4	0.6	-	-	0.4
a₄₂	14	1.6	0.5	3.2	0.8	0.6	-	0.3	-	0.4
a₄₃	15	1.8	0.5	3.4	0.6	0.6	-	0.4	-	0.4

Table XXX

Aluminum alloy	Fatigue limit (Kg/mm²)	Amount of hydrogen gas (cc/100g alloy)
a₃₀	14.0	10
a₃₁	14.2	9
a₃₂	13.2	7
a₃₃	14.6	8
a₃₄	14.0	6
a₃₅	13.2	8
a₃₆	14.6	10
a₃₇	14.2	9
a₃₈	14.2	7
a₃₉	13.6	10
a₄₀	14.8	8
a₄₁	14.0	9
a₄₂	14.6	10
a₄₃	14.8	7

The above-described spring retainer can be subjected to a thermal treatment to improve the stress corrosion and crack resistance thereof.
For such thermal treatment, the following four methods are applied.

(a) Aging at Room Temperature

The spring retainer is heated at 490°C for two hours and then cooled with water. Thereafter, the spring retainer is subjected to a natural aging at room temperature for 4 days.

(b) Overaging

The spring retainer is heated at 460 to 510°C for 1 to 4 hours and then cooled with water. Thereafter, the spring retainer is subjected to an aging at 210 to 240°C for 0.5 to 4.0 hours.

(c) Two Stage Aging (First stage: Aging at Room Temperature)

The spring retainer is heated at 460 to 510°C for 1 to 4 hours and then cooled with water. Thereafter, the spring retainer is subjected to an aging at room temperature for 4 days. After this aging at room temperature, the spring retainer is subjected to an aging at 210 to 240°C for 0.5 to 4.0 hours.

(d) Two Stage Aging (First stage: Artificial Aging)

The spring retainer is heated at 460 to 510°C for 1 to 4 hours and then cooled with water. Thereafter, the spring retainer is subjected to aging at 150 to 200°C for 0.5 to 4.0 hours.
After such artificial aging, the spring retainer is subjected to an aging at 210 to 240°C for 0.5 to 4.0 hours.

Claims

A high strength aluminum alloy for a mechanical structural member, said alloy comprising
a matrix formed from an aluminum alloy powder; and
a hard grain dispersed in said matrix;
said hard grain being at least one selected from grains of Al₂O₃, SiC, Si₃N₄, ZrO₂, SiO₂, TiO₂, Al₂O₃-SiO₂ and metal Si;
the amount of hard grain added being in a range from 0.5% to 20% by weight;
the area rate of said hard grain (ie. the percentage coverage of the surface of said member by hard grain) being in the range of from 1% to 6%;
the average particle size D of said hard grain being such that 3 »m ≦ D ≦ 30 »m;
the hardness Hv of said hard grain being such that 700 ≦ Hv < 1000; and
when $K = (L + 0.5) (D-1)$
in said range of the hardness Hv (wherein the % by weight of hard grain added is represented by L), the condition 200 < K ≦ 600 is satisfied.
A high strength aluminum alloy for a mechanical structural member, said alloy comprising
a matrix formed from an aluminum alloy powder; and
a hard grain dispersed in said matrix;
said hard grain being at least one selected from grains of Al₂ O₃, SiC, Si₃N₄ , ZrO₂, SiO₂, TiO₂, Al₂O₃ -SiO₂ and metal Si;
the amount of hard grain added being in a range from 0.5% to 20% by weight; and
the area rate of said hard grain (ie. the percentage coverage of the surface of the member by hard grain) being in the range of from 1% to 6%;
the average particle size D of said hard grain is such that 3 »m ≦ D ≦ 30 »m;
the hardness of Hv of said hard grain is such that 1000 ≦ Hv < 1500; and
when $K = (L + 0.5) (D - 1)$
in said range of the hardness Hv (wherein the % by weight of hard grain added is represented by L), the condition 80 < K ≦ 200 is satisfied.
A high strength aluminum alloy for a mechanical structural member, said alloy comprising
a matrix formed from an aluminum alloy powder; and
a hard grain dispersed in said matrix;
said hard grain being at least one selected from grains of Al₂ O₃, SiC, Si₃ N₄, ZrO₂, SiO₂, TiO₂, Al₂ O₃ -SiO₂ and metal Si;
the amount of hard grain added being in a range from 0.5% to 20% by weight; and
the area rate of said hard grain (ie., the percentage coverage of the surface of the member by hard grain) being in the range of from 1% to 6%;
the average particle size D of said hard grain is such that 3 »m ≦ D ≦ 30 »m;
the hardness Hv of said hard grain is such that 1500 ≦ Hv < 2000; and
when $K = (L + 0.5) (D - 1)$
in said range of the hardness Hv (wherein the % by weight of hard grain added is represented by L), the condition 35 < K ≦ 80 is satisfied.
A high strength aluminum alloy for a mechanical structural member, said alloy comprising
a matrix formed from an aluminum alloy powder; and
a hard grain dispersed in said matrix;
said hard grain being at least one selected from grains of Al₂ O₃, SiC, Si₃ N₄, ZrO₂, SiO₂, TiO₂, Al₂ O₃ -SiO₂ and metal Si;
the amount of hard grain added being in a range from 0.5% to 20% by weight; and
the area rate of said hard grain (ie., the percentage coverage of the surface of the member by hard grain) being in the range of from 1% to 6%;
the average particle size D of said hard grain is such that 3 »m ≦ D ≦ 30 »m;
the hardness Hv of said hard grain is such that 2000 ≦ Hv ≦ 3000; and
when $K = (L + 0.5) (D - 1)$
in said range of the hardness Hv (wherein the % by weight of hard grain added is represented by L), the condition 13 ≦ K ≦ 35 is satisfied.
A high strength aluminum alloy as claimed in any of the preceding claims, wherein said matrix is formed from a quenched and solidified aluminum alloy powder.
A high strength aluminum alloy as claimed in any of the preceding claims, comprising:
a matrix formed from an aluminum alloy consisting of
12.0% by weight ≦ Si ≦ 28.0% by weight;
0.8% by weight ≦ Cu ≦ 5.0% by weight;
0.3% by weight ≦ Mg ≦ 3.5% by weight;
2.0% by weight ≦ Fe ≦ 10.0% by weight;
0 5% by weight ≦ Mn ≦ 2.9% by weight;
the balance of aluminum including unavoidable impurities.
A high strength aluminum alloy as claimed in any one of the preceding claims, comprising 0.2% to 4% by weight of at least one hydride forming constituent selected from Ti, Zr, Co, Pd and Ni.
A mechanical structural member manufactured from a high strength aluminum alloy as claimed in any one of claims 1 to 7.
A valve spring retainer for a valve operating mechanism for an internal combustion engine, said retainer being manufactured from a high strength aluminum alloy as claimed in any one of claims 1 to 7.
A valve spring retainer as claimed in claim 9, wherein said retainer includes a flange portion at one end of an annular base portion and having a larger diameter than that of the base portion, with an annular end face of said flange portion serving as an outer seat surface for carrying an outer valve spring and with an annular face end of said base portion serving as an inner seat surface for carrying an inner valve spring, the flow pattern of the fiber structure of a material in a surface layer region having said outer seat surface being substantially parallel to said outer seat surface.
A valve spring retainer as claimed in claim 9 or claim 10, wherein the ratio a/b of the area rate a of said hard grain on said outer seat surface to the area rate b of said hard grain on said inner seat surface is such that 1.05 ≦ a/b ≦ 1.50.
A valve spring retainer as claimed in any of claims 9 to 11, wherein the flow pattern of the fiber structure of the material in said surface layer region is continuous with the axial flow pattern of the fiber structure of the material in the surface layer region of the base portion.
A valve spring retainer as claimed in any one of claims 9 to 12, wherein said base portion has an annular projection provided thereon and projecting from an inner peripheral edge of said inner seat surface, and wherein if the axial length between an outer end face of said flange portion and an outer end face of said projection is represented by L1, and the axial length between the outer end face of said flange portion and said inner seat surface is represented by L2, then L2 > 1/2 L2, and if the axial length between said outer seat surface and said inner seat surface is represented by L3, the axial length between the outer end face of said flange portion and said outer seat surface is represented by L4, and the axial length between the outer end face of said projection and said inner seat surface is represented by L5, then L3 > L4 and L3 > L5.
A valve spring retainer as claimed in any one of claims 9 to 13, wherein outer peripheral surfaces of both said base portions and said projection are formed into tapered surfaces convergent toward the outer end face of said projection.
A valve spring retainer as claimed in claim 14, wherein the entire periphery of an opening at the outer face end of said projection in a valve stem mounting hole made through said flange portion, said base portion and said projection is rounded.
A valve spring retainer as claimed in any of claims 9 to 15, which is formed from a quenched and solidified aluminum alloy containing 0.2% to 4% by weight of at least one hydride forming constituent selected from Ti, Zr, Co, Pd and Ni.
A valve spring retainer as claimed in any of claims 9 to 16, which is formed from a quenched and solidified aluminum alloy containing 12.0% to 28.0% by weight of Si; 0.8% to 5.0% by weight of Cu; 0.3% to 3.5% by weight of Mg; 2.0% to 10.0% by weight of Fe; 0 5% to 2.9% by weight of Mn; and 0.2% to 4% by weight of at least one hydride forming constituent selected from Ti, Zr, Co, Pd and Ni.